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MBE 4000 EGR COOLER AND COOLER SUPPORT BRACKET

The EGRsystem is equipped with a single-pass cooler. Exhaust gasses coming from the first three cylinders are directed through the EGRshut off valve, through the cooler and reed valves, past the EGR control valve and the mixer, then back to the cylinder. ‪

EGRCooler and Support Bracket Removal

Remove the EGRcooler and its support bracket as follows: ‪

Note: The exhaust manifold and the gas inlet pipe have already been removed at this point. It is then possible to remove the cooler and support bracket without removing the throttle valve first.

  1. Disconnect the coolant vent line located on top of the EGRcooler. See Figure 44133 .

    1. Coolant Outlet Pipe Bolts ‪

    4. EGRCoolant Outlet Pipe ‪

    2. Coolant Vent Line ‪

    5. Coolant Outlet Pipe Bracket ‪

    3. Membrane ‪

    Removal of Coolant Vent Line and Coolant Outlet Pipe

  2. Remove the bolt attaching the coolant outlet pipe bracket to the pipe. Remove the bracket.
  3. Remove the two bolts attaching the coolant outlet pipe flange to the coolant pump. Discard the gasket.
  4. Pull the coolant outlet pipe away from the cooler, leaving the connecting membrane in the EGR cooler boss.
  5. Remove the EGRtemperature sensor from the reed valve housing and disconnect the sensor wiring harness where it is attached with cable ties to the reed valve housing mounting bracket. See Figure 44143 .

    1. EGRAir Temperature Sensor ‪

    2. Reed Valve Housing Bracket ‪

    Removing EGRAir Temp. Sensor

  6. Remove the three bolts from the front bracket that holds and stabilizes the reed valve housing to the thermostat housing. See Figure 44143 .
  7. Remove the two front sheet metal support-to-cooler support bolts(See number 1 in graphic). See Figure 44139 .

    1. Front Sheet Metal Support-to-Cooler Support Bolts ‪

    3. EGRCooler-to-Sheet Metal Support bolts ‪

    2. Front Sheet Metal Support ‪

    Removing Front Sheet Metal Support

    Note: Do not remove the eight mounting bolts attaching the reed valve housing to the cooler at this time. Also, do not remove the two EGRcooler-to-sheet metal support bolts at this time. They will all be removed once the EGRcooler as an assembly is taken off of the engine.

  8. Remove the two bolts mounting the lower coolant inlet pipe to the block and remove the bracket bolt, just below the membrane, which attaches the lower coolant inlet pipe to the block. Remove gasket. See Figure 44141 .

    1. Lower Coolant Inlet Pipe ‪

    4. Shut off Valve Housing Bolt (2 qty.) ‪

    2. Membrane ‪

    4. Air Supply Line ‪

    3. Air Line Mounting Bolts ‪

    Removing Coolant Inlet Pipe

  9. Pull down on the lower coolant inlet pipe to loosen it from the upper pipe. Remove the membrane also.

    Note: Have a container nearby to drain any unused coolant from the inlet pipes.

  10. Remove the two shut off valve housing bolts that hold the valve housing to the EGRcooler support. See Figure 44141 .
  11. Remove the air line mounting bolts. Loosen and remove the air supply line from the EGRshut off valve. See Figure 44141 .
  12. Loosen and remove the four bolts from the four clamps that are holding the EGRcooler to the cooler support bracket. Remove the four clamping pieces for clamps also. See Figure 44140 .

    1. EGRCooler ‪

    3. Clamps (4 Qty.) ‪

    2. Clamping Pieces (4) ‪

    4. Clamp Bolts ‪

    Removing Clamps on the Cooler

    Note: The oil filter and oil filter cover should be removed for good clearance when removing and installing the EGRcooler assembly.

  13. With the cooler completely loosened at this point, pull the cooler housing flange away from the EGRcontrol valve. As the cooler is lifted, slide the cooler inlet pipe up through the opening in the cooler support bracket. See Figure 44128 .

    1. Cylinder Heads ‪

    4. EGRCooler ‪

    2. EGRCoolerTightening Clamps ‪

    5. EGRCooler Support ‪

    3. Tightening Tool for Clamps ‪

    Removing EGRCooler

    Note: Before removing the eight bolts from the EGRcooler support, insert the four guide studs into the exhaust manifold gasket holes to support the gaskets once the cooler support is removed.

  14. Remove the eight mounting bolts from the EGRcooler support and remove the support from cylinder heads. See Figure 44131 .

    1. M10 x 65 mm bolts ‪

    2. M10 x 45 mm bolts ‪

    Removing the EGRCooler Support

  15. Remove the eight mounting bolts from the EGRcooler flange, which houses the reed valves. See Figure 44144 .

    1. EGRCooler-to- Sheet Metal Support Bolts ‪

    2. EGRCooler Flange Bolts ‪

    Removing the EGR Cooler Flange

  16. Remove the two EGRcooler-to-sheet metal support bolts. See Figure 44144 .
  17. Remove the reed valves from housing. See Figure 44146 .

    1. EGRCooler Housing ‪

    4. EGRReed Valve Flange ‪

    2. EGRCooler Gasket ‪

    5. Reed Valves ‪

    3. EGRCooler Intermediate Flange ‪

    Removing the EGRCooler Flange and Components

  18. Remove the intermediate flange and gasket from cooler flange assembly. See Figure 44146 .

EGRCooler and Support Bracket Installation

Install the EGRcooler and the EGRcooler support bracket as follows: ‪

Note: Exhaust manifold gaskets will have to be installed before EGRcooler support or cooler can be installed. Refer to section .

  1. Install coolant outlet pipe. Install the two M8 x 25 mm bolts through the coolant pipe flange, metal gasket and into the coolant pump. Leave loose until the cooler assembly is installed, then torque bolts to 35 Nm (26 lbft). See Figure 44133 .

    1. Coolant Outlet Pipe Bolts ‪

    4. EGRCoolant Outlet Pipe ‪

    2. Coolant Vent Line ‪

    5. Coolant Outlet Pipe Bracket ‪

    3. Membrane ‪

    Installation of Coolant Outlet Pipe

    Note: Coolant outlet pipe must be installed to coolant pump before the EGRcooler support and cooler are installed.

  2. Install the cooler support to the cylinder heads using the eight mounting bolts. Torque all bolts to 25 Nm (19 lbft). See Figure 44131 .

    1. M10 x 65 mm bolts ‪

    2. M10 x 45 mm bolts ‪

    Installing EGRCooler Support

    Note: If at this point the exhaust manifold gasket studs are still in place, they will need to be removed.

    Note: Assemble and attach the EGRreed valve housing to the cooler before mounting the cooler to the cooler support.

  3. Insert the reed valves into the EGRreed valve housing flange.
  4. Assemble the EGRreed valve housing flange, cooler intermediate flange, gasket and front sheet metal support together. Attach all to the cooler housing using the eight mounting bolts. Torque the bolts to 10 Nm (8 lbft). See Figure 44144 .

    1. EGRCooler-to- Sheet Metal Support Bolts ‪

    2. EGRCooler Flange Bolts ‪

    Installing the EGRCooler Flange

  5. Attach the EGRcooler to the front sheet metal support with two bolts. Torque to 25 Nm (19 lbft). See Figure 44144 .
  6. Using industrial petroleum grease, insert a membrane into the side of the EGRcontrol valve that is closest to the EGRcooler. See Figure 44136 .

    1. Symmetric membrane ‪

    2. EGRTemperature Sensor ‪

    Installing Symmetric Membrane into EGRValve

  7. Lift entire EGRcooler with attached cooler flange and sit this on top of cooler support, taking care to insert the upper half of the coolant inlet pipe down through the appropriate hole in the cooler support. At the same time, push the cooler flange into the membrane. See Figure 44136 .

    Note: The oil filter and oil filter cover should be removed for good clearance when removing and installing the EGRcooler assembly.

  8. Insert the connecting membrane in the EGR cooler boss using industrial petroleum grease and push the EGRcoolant outlet pipe onto the cooler. See Figure 44133 .

    1. Coolant Outlet Pipe Bolts ‪

    4. EGR Coolant Outlet Pipe ‪

    2. Coolant Vent Line ‪

    5. Coolant Outlet Pipe Bracket ‪

    3. Membrane ‪

    Installation of Coolant Vent Line and Coolant Outlet Pipe

  9. Attach front sheet metal support-to-cooler support using two M8 x 12 mm bolts. Torque to 25 Nm (19 lbft).
  10. Install the bolt to the coolant outlet pipe bracket. Torque to 35 Nm (26 lbft). See Figure 44133 .
  11. Install coolant vent line. Torque to 25 Nm (19 lbft).
  12. Install the reed valve-housing bracket to the thermostat housing with the three mounting bolts. Torque to 25 Nm (19 lbft). See Figure 44143 .
  13. Install the EGRair temperature sensor into reed valve housing flange. Torque to 25 Nm (19 lbft). Using plastic ties, attach remainder of sensor to reed valve-housing bracket. See Figure 44143 .

    NOTICE:

    There is a possibility of installing the air temperature sensor wrong-sided. Take care to install it properly. ‪

    1. EGRAir Temperature Sensor ‪

    2. Reed Valve Housing Bracket ‪

    Installing the EGRAir Temperature Sensor and Housing Bracket

  14. Install the four clamping pieces and four clamps that hold the EGRcooler to the cooler support bracket. Torque to 10 Nm (7 lbft). See Figure 44140 .

    1. EGRCooler ‪

    3. Clamps (4 Qty.) ‪

    2. Clamping Pieces (4) ‪

    4. Clamp Bolts ‪

    Installing Clamps on the Cooler

  15. Fit lower coolant inlet pipe into the symmetric membrane. Install the two bolts in the metal gasket and engine block. Also install bolt in pipe support bracket. Torque both bolts to 35 Nm (26 lbft). See Figure 44141 .

    1. Lower Coolant Inlet Pipe ‪

    4. Shut off Valve Housing Bolt (2 qty.) ‪

    2. Membrane ‪

    5. Air Supply Line ‪

    3. Air Line Mounting Bolts ‪

    Installing Coolant Inlet Pipe

  16. Install EGRshutoff valve and secure using two bolts. Torque to 35 Nm (26 lbft).
  17. Install and attach air supply line using two mounting bolts.
EGRCooler Inspection

In the event there is a suspected EGRcooler leak, inspect the engine for the following symptoms: ‪

  • Excessive coolant consumption identified by the Amber Warning Lamp (AWL) for low coolant level.
  • Black traces of a liquid on the rear right side of engine block, near the shutoff-valve.
  • Black soot on the inside surface of the heat shield and the mounting bracket for the EGRshutoff-valve.
  • Leaking water or coolant traces around the EGRvalve, outlet pipe, or shutoff-valve. See Figure 44792 .

    Leaking Water or Coolant Traces near Shutoff-Valve

    Note: Water condensation can generate water/coolant traces around EGRcomponents. Water condensation does not imply that there is a component failure. In the case of a leaking EGRcooler, the water/coolant traces in the EGRcomponents are always associated with coolant consumption. Check the Amber Warning Lamp (AWL) for low coolant level.

    See Figure 44793 for the flowhart of checking the coolant system for leaks. This flowchart must be applied to engines with excessive loss of coolant or for a low coolant level warning on the AWL. ‪

    Flowchart for Checking Coolant System for Pressure Leaks

    Note: New coolant pipes have been added to the coolant system (EGRcooler supply and return lines). Make sure that they also are inspected for leaks during the coolant system pressure test.

EGRCooler Leak Test

Perform the following steps to conduct a cooler leak test: ‪

  1. Short-circuit or plug the coolant ports on the EGRcooler. See Figure 44794 for details.

    1. EGRCooler Ports ‪

    3. Vent Line ‪

    2. EGRCooler ‪

    4. Circuit Hose ‪

    EGRCooler Ports Closed

  2. Connect an air supply with a pressure regulator and pressure gauge to the EGRcooler vent line.

    EYE INJURY

    To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 40 psi (276 kPa) air pressure.

  3. Pressurize the EGRcooler to 90 kPa (13 psi). When adjusting the pressure, do not exceed 103 kPa (15 psi).

    BURNS

    To avoid injury from burning, use lifting tools and heat-resistant gloves when handling heated components.

  4. Submerge the EGRcooler completely in a hot water tank. Tip one end of the cooler up so that air bubbles will quickly escape.
  5. Leave the EGRcooler submerged for five minutes.
  6. In the event of a failed EGRcooler, a steady stream of small air bubbles will come out of the highest end of the EGRcooler.
  7. Replace the EGR cooler.